Project

Description

Development, Implementation, and Validation of Test Systems for Strategic and Advanced Environmental Testing in the Aerospace Sector. SpaceLAB aims to develop test systems for the aerospace sector, focusing on critical tests for the qualification of components and subsystems for satellites. The objective is to optimize product development performance by reducing the number of tests and improving in-service reliability. The key areas of interest are Pyroshock and vacuum outgassing tests, with significant innovative and strategic impact at both regional and national levels. SpaceLAB intends to make these advanced technologies accessible to local companies, promoting economic and social development through the establishment of dedicated laboratories and state-of-the-art test machinery.

Objectives

SpaceLAB aims to conduct tests and simulations to predict and enhance the behavior of satellites and onboard instruments to be sent into space, drastically reducing in-service incidents and failures. Improving the efficiency of onboard instrumentation is an objective that impacts daily life, considering the activities that satellites perform daily on Earth’s status, such as monitoring pollution, traffic, mobility, public health, etc.

Activity plan

The SpaceLAB project has two primary focuses: the development of a test bench for Pyroshock and the development of a test bench for Outgassing.

Outgassing tests:

The development of this test bench is based on using "DTM" test equipment to simulate conditions similar to those in the space vacuum. An upgrade to the equipment will be designed, which will include the installation of a TQCM system (Termoelectric Quarz Crystal Micro Balance), the necessary acquisition and cooling systems to conduct the test. Outgassing can cause contamination and affect the functionality of systems so the use of TQCM sensor is essential as it will guarantee precise use in measuring mass changes at the nanogram level and play important role in qualifying the aerospace components.

Pyroshock Tests:

Pyroshock is the dynamic structural shock that occurs when an explosion or impact occurs on a structure. Pyroshock testing is of particular relevance to the defense and aerospace industries because it serves to verify the structural and/or functional resistance to vibration occurring during launch phase and/or in the following phases, like structural subsystems separation (e.g., payloads from launch vehicles), deploy appendages (e.g., solar panels). The test bench will be designed, validated on a small scale prototype, realized on full scale and then validated in an industrial environment during the Project development.The first step for the realization of the test bench is the model of the main dynamics of the test to enable the simulation of various experimental setup configurations in a short time, followed by the development of a predictive Pyroshock model, which is essential for equipment design and experimental validation.

Pyroshock Tests: Pyroshock is the dynamic structural shock that occurs when an explosion or impact occurs on a structure. Pyroshock testing is of particular relevance to the defense and aerospace industries because it serves to verify the structural and/or functional resistance to vibration occurring during launch phase and/or in the following phases, like structural subsystems separation (e.g., payloads from launch vehicles), deploy appendages (e.g., solar panels). The test bench will be designed, validated on a small scale prototype, realized on full scale and then validated in an industrial environment during the Project development.The first step for the realization of the test bench is the model of the main dynamics of the test to enable the simulation of various experimental setup configurations in a short time, followed by the development of a predictive Pyroshock model, which is essential for equipment design and experimental validation. . Outgassing tests: The development of this test bench is based on using DTM test equipment to simulate conditions similar to those in the space vacuum. An upgrade to the equipment will be designed, which will include the installation of a TQCM system and the necessary acquisition and cooling systems to conduct the test.

The first figure (Click to enlarge.) shows an example of the study of the resonant plate to use in the Pyroshock test. In figure, some of the modes are presented. Knowing where the main modes are, is essential to position the device under test. The model is also able to foresee the Shock Response Spectrum (SRS) of different plates. In figure 2 it is possible to see a comparison between a small scale plate and a full scale one. In figure 3 there is a comparison among the SRS of different plates. In the last figure it is possible to see the comparison between the SRS obtained with the model and the one resulting from the experimental measurements on a plate with the same dimensions used for the simulation.

Results

Design and build a test bench for Pyroshock tests

Develop and integrate Pyroshock test design and optimization techniques into a single software

Define a new CAx methodology to guide design activities to predict how to modify the design and structure to withstand the required shock during testing

Design and develop the Outgassing test system, implementing a surface contamination measurement device under vacuum conditions with TQCM sensors